Container assembly including a detachable follow plate for loading bulk material therefrom

ABSTRACT

The invention relates to a container assembly that includes a built-in follow plate for loading a viscous fluid into the barrel of a dispensing device. The assembly includes a drum for holding a viscous fluid therein and a lid for fitting over the drum open top to effect closure of the drum. The assembly includes a horizontally oriented follow plate detachable from the lid. The follow plate includes a central hub arranged for receiving the barrel of a dispensing device. The follow plate moves in response to a change in the level of fluid in the drum as it is drawn into the barrel of the dispensing device.

This application claims the benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/723,349, filed on Nov. 7, 2012 entitled CONTAINER ASSEMBLY INCLUDING A DETACHABLE FOLLOW PLATE FOR LOADING BULK MATERIAL THEREFROM, the disclosure of which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

This invention relates generally to dispensing materials from a container (drum, barrel, pail, etc.) using apparatus including a follower plate which is lowered into the drum housing the material to be dispensed. In particular, the invention relates to a follow plate that is detachable from a drum lid and is low cost and disposable.

The viscosity of materials to be dispensed using apparatus of the present invention varies depending upon the specific application, and it is not unusual to find materials which are not particularly viscous and are substantially free flowing. On the other hand in certain applications such materials may be extremely viscous and require the application of considerable heat and/or pressure in order to render such materials dispensable. The present invention is applicable to apparatus for dispensing highly viscous materials and also useful with substantially free flowing materials.

In one form of apparatus of the type contemplated by the present invention a follow plate is caused to be lowered into open end of a drum-like container housing the material to be dispensed. In operation, as the follow plate enters the drum it engages the inside surface of the drum and the material therein. As the follow plate travels towards the closed base of the drum it causes the material sandwiched or pressured therebetween to be dispensed, as for example, by forcing the material through an opening in the follow plate. The follow plate fits within the end of the drum and “follows” the fluid level in the drum as the fluid is withdrawn from the drum. The follow plate is often used for loading bulk caulking material or epoxy into the barrel of a device or gun for dispensing such materials. The barrel defines a cylindrical chamber into which the caulking material or epoxy is drawn prior to dispensing. The barrel is attached to an opening in the follow plate and by retracting a piston rod within the barrel of the dispensing device, the caulking material or epoxy may be drawn from the drum into the barrel for dispensing.

There are a number of problems associated with the use of such follow plates. Usually, such follow plates are made of metal parts, and/or multiple components, and therefore can be costly. For this reason, disposal of the follow plate after a single use is not preferred. Rather, it is necessary to remove the follow plate from the spent drum for reuse in the next drum. Often this can be a difficult and time consuming effort because residual viscous material remaining in the drum that may have begun to cure will impede easy removal of the follow plate. Often the follow plate will be provided with a hook or a tab to facilitate such removal of the follow plate from the drum for reuse. Removal of the follow plate from the drum can be also difficult due to the weight of the follow plate. Accordingly, it is an object of the present invention to overcome these difficulties by developing a low cost follow plate that is detachable from a container lid and can be disposed of with the drum when the contents of the drum has been emptied.

BRIEF SUMMARY OF THE INVENTION

The invention relates to a container assembly having a lid that includes a built-in follow plate for loading a viscous fluid into the barrel of a bulk dispensing device. Alternatively, the follow plate may be arranged for attaching to a hose, pipe, tubing, etc., for dispensing. The assembly includes a drum for holding a viscous fluid therein, the drum including an open top, a central axis, and an inner side wall. The assembly includes a lid having a peripheral channel arranged for fitting over the drum open top to effect closure of the drum. The lid also includes an annular skirt extending inwardly from the peripheral channel to define a central opening. The assembly also includes a horizontally oriented follow plate detachable from the lid by means of a pull tab. The follow plate includes an opening, e.g., a central hub, arranged for receiving the barrel of a bulk dispensing device. Alternatively, the central hub could be arranged for attaching to a hose, pipe, tubing or other useful attachment for dispensing. The follow plate is movable by external means along the central axis of the drum in response to a change in the level of fluid in the drum as it is drawn into the barrel of the bulk dispensing device. The follow plate includes an outer periphery that is in sliding engagement with the drum inner side wall.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:

FIG. 1 is an isometric view of prior art container assembly of the present invention;

FIG. 2 is an isometric view of a prior art container assembly of the present invention;

FIG. 3 is a sectional view taken along line 3-3 of FIG. 2;

FIG. 4 is sectional view illustrating the prior art follow plate “following” the material downwardly as material is being suctioned into the barrel of a bulk dispensing device or other attachment;

FIG. 5 is a perspective view of an embodiment of the container assembly of the present invention illustrating the follow plate assembly integral with the pail or drum lid;

FIG. 6 is an isometric view of a portion of an embodiment of the container assembly of the present invention illustrating the follow plate assembly integral with the pail or drum lid;

FIG. 7 is a sectional view of an embodiment of the container assembly of the present invention showing the follow plate attached to the lid in contact with material inside the pail or drum;

FIG. 8 is a sectional view taken along line 8-8 of FIG. 6;

FIG. 9 is a cross sectional view of a container assembly of the present invention illustrating a second embodiment of the follow plate assembly integral with the pail or drum lid;

FIG. 10 is a cross sectional view of the container assembly of FIG. 9 illustrating the second embodiment follow plate illustrating the manner for separating the follow plate assembly from the lid of the pail; and,

FIG. 11 is a cross sectional view of the container assembly of FIG. 9 illustrating the second embodiment follow plate during loading of viscous material into the barrel of a bulk dispensing device.

DETAILED DESCRIPTION OF THE INVENTION

Under the prior art, illustrated in FIGS. 1-4, a container assembly 10 is provided to the user in a pre-filled condition with the viscous material 18 located within the drum 14. A lid (not shown) is removed and a follow plate 19 of the prior art is inserted to contact the viscous material 18. Next, as shown in FIGS. 1-4, the user attaches a barrel 53 of a bulk dispensing device to a central hub 21 of the follow plate 19 and applies downward pressure as indicated by arrow 17 in FIG. 4. As best illustrated in FIGS. 3 and 4, as a result of this downward pressure, the viscous material 18 will begin to flow upwardly through the central hub 21 of the follow plate 19 and into the barrel 53 of the dispensing device. Simultaneously, the user pulls back on the piston rod 23 of the dispensing device in the direction indicated by arrow 24 to draw the viscous material 18 into the dispenser barrel 53 until the barrel 53 is filled. Once filled, the barrel 53 can be removed from the central hub 21 and bulk material can be dispensed from the dispensing device. As bulk viscous material 18 is repeatedly drawn from the drum 14, the follow plate 19 moves towards the bottom of the drum 14. Once the follow plate 19 reaches the bottom of the drum 14, the follow plate 19 is removed from the bottom of the drum 14 for re-use, which can be difficult and time-consuming for reasons stated above.

Referring now to an embodiment of the present invention, there is shown in FIGS. 5 through 8 a container assembly including a drum 14 for containing and dispensing therefrom a viscous material 18 such as an epoxy or caulking material. The drum 14 includes a base 22 and a side wall 26 extending upwardly from the outer periphery of the base 22 to an upper edge 30 (FIGS. 7 and 8). A lid 34 is provided for covering the drum 14 during sale, shipping, and use. The lid 34 includes an annular upper wall 38 and an annular lower wall 42. An inner annular lip 46 protrudes downwardly from an inner circumference of the annular upper wall 38 to connect the annular upper wall 38 to the annular lower wall 42. An annular outer wall 50 extends downwardly from the annular upper wall 38. Together, the outer wall 50, annular wall 38 and annular lip 46 form a peripheral channel for fitting over the upper edge 30 of the drum 14. The annular lower wall 42 defines an opening 52 (FIG. 8). By providing the opening 52, the lid 34 may remain in place over the drum 14 during loading of the viscous material 18 from the drum 14 into the barrel of a bulk dispensing device (not shown).

The annular lower wall 42 includes a bottom surface to which a disposable follow plate 54 is attached by any suitable means. In one embodiment shown in FIGS. 5 through 7, a “break away” mechanism or “pull-tab” 58 is interposed in the form of a strip between the lower wall 42 bottom surface and the follow plate 54. The pull tab 58 may be attached to the bottom surface of the lower wall 42, as well as to the follow plate 54 by any suitable method, e.g., overmolding. As best illustrated in FIG. 6, a pulling force 59 may be applied to the pull tab 58 to remove the follow plate 54 from the lid 34 when it is desired to load a barrel 53 of a bulk dispensing device (not shown) with viscous material 18 provided in bulk within the drum 14.

The follow plate 54 may be made of any suitable material, such as a nitrile rubber, neoprene, metal, plastic, or another suitable chemical resistant material. In another embodiment, the material forming the follow plate 54 may be of any suitable material hardness, e.g., (Shore A) in the range of 70A to 90A. The follow plate 54 may be provided with an integral central hub 62 in the form of a cylinder having an open top and an open bottom to enable a user to draw viscous material 18 from within the drum 14. The follow plate 54 includes a plurality of reinforcement ribs 64 that extend radially from the central hub 62 to the periphery thereof, or can be made of another suitable design for reinforcement.

As the follow plate 54 is lowered into the drum 14 and engages the viscous material 18, there is a tendency for the viscous material to flow from the bottom of the follow plate 54 over the top of the follow plate 54 at the peripheral surface or edge thereof where the follow plate abuts the inside surface of the drum 14. For example, in those instances where the follow plate 54 is cylindrical and is caused to extend into a cylindrical drum 14 for purposes of dispensing viscous material 18 from within the drum 14, there is a tendency for the viscous material 18 to flow or leak between the outer periphery of the follow plate 54 and the inside surface of the drum 14. In order to prevent such leakage and to direct substantially all of the viscous material 18 through the central hub 62, for example, the follow plate 54 discussed above may be encircled with one of more resilient sealing means which serve to scrape the inside surface of the drum 14 and also to prevent or reduce leakage at the interface between the inside surface of the drum and the periphery of the follow plate. Alternatively, as best shown in FIGS. 7 and 8, towards its periphery, the follow plate 54 is reduced in thickness to facilitate sliding engagement with the inner side wall of the drum 14.

In one embodiment, the central hub 62 may include an outer diameter that is sized to fit within the inner diameter of a barrel 53 of a dispensing device (FIGS. 1-4). A cap 66 arranged to be fitted over the central hub 62 and may be removed from the central hub 62 by applying a pulling force to a pull tab 70 integral with the cap 66, the pull tab 70 that is similar to a “tamper-evident” ring commonly used on a plastic milk container. In one embodiment, once the cap 66 has been removed from the central hub 62, the barrel 53 of a dispensing gun (FIGS. 1-4) may be placed over the central hub 62 of the follow plate 54 to provide an interference fit between the inner diameter of the dispensing device barrel (not shown) and the outer diameter of the central hub 62 to create a seal for drawing viscous material 18 into the dispensing device barrel (not shown). Under this embodiment there are no internal or external threads utilized for securing the barrel (not shown) to the central hub 62. Alternatively, the central hub 62 of the follow plate 54 could be sized to enable the bulk dispensing device (not shown) to be placed within the central hub 62 to provide an interference fit between the outer diameter of the barrel (not shown) and the inner diameter of the central hub 62 to create a similar seal for drawing viscous material 18 into the barrel (not shown). In an alternative embodiment (not shown) the internal surface of the barrel (not shown) could be provided with threads and the central hub 62 provided with external threads to enable threaded engagement between the dispensing device barrel (not shown) or any other connection meant for dispensing, and the central hub 62.

In use, the container assembly 10 is provided to the user in a pre-filled condition with the viscous material 18 located within the drum 14. The container assembly 10 is provided with the lid 34 fitted over the upper edge 30 of the drum 14 and the removable pull tab 58 attaching the follow plate 54 to the underside of the lid 34. Without removing the lid 34 from the drum 14, the user may remove the pull tab 58 to separate the follow plate 54 from the underside of the lid 34. Next, the cap 66 may be removed by pulling pull tab 70 to expose the central hub 62 of the follow plate 54. Next, as best shown in FIGS. 7 and 8, the user applies downward pressure (indicated by arrow 72) on the follow plate 54 until it makes contact with the viscous material 18 within the drum 14. As a result of this downward pressure, viscous material 18 will begin to flow upwardly through the central hub 62. Once material reaches the tip of the central hub 62, the user will extend the bulk dispenser barrel (not shown) through the lid opening 54 and install the barrel directly over the central hub 62 to create a positive seal between the barrel (not shown) and the central hub 62. Next, using the bulk dispensing device, the user pushes down on the follow plate 54 while simultaneously pulling up on the piston rod (not shown) of the bulk dispenser to draw viscous material into the dispenser barrel (not shown) until the dispenser barrel is filled. Once filled, the barrel can be removed from the central hub 62 and bulk material can be dispensed from the dispensing device. As bulk viscous material 18 is repeatedly drawn from the drum 14, the follow plate 54 moves towards the bottom of the drum 14. Once the follow plate 14 reaches the bottom of the drum 14, it can be disposed of along with the drum 14 and attached lid 34. Alternatively, the user can install a connection device to the follow plate hub (such as a hose, pipe, or tube) to dispense material from the drum.

Referring now to FIGS. 9-11, there is shown a second embodiment 100 of the present invention including an alternative follow plate 154 which is shown attached by any suitable means to the bottom surface of a lower annular wall 142 of a lid 134 provided for covering a drum 114 containing a viscous material during sale, shipping, and use. The lid 134 is substantially the same as that of the first embodiment, in that it includes an annular upper wall 138, the annular lower wall 142, and an annular lip 146 extending at an inclined angle to connect the upper and lower annular walls, 138, 142 respectively. Together, the outer wall 150, annular upper wall 138 and annular lip 146 form a peripheral channel for fitting over an upper edge 130 of the drum 114. The annular lower wall 142 defines an opening 152 (FIG. 11) to enable the lid 134 to remain in place over the drum 114 during loading of the viscous material 118 from the drum 114 into a barrel 115 of a bulk dispensing device.

A “break away” mechanism or “pull-tab” 158 (FIG. 9) is interposed in the form of a strip between the lower wall 142 and the follow plate 154. The pull tab 158 may be attached to the lower annular wall 142, as well as to the follow plate 154 by any suitable method, e.g., overmolding. As described in the earlier embodiment, a pulling force may be applied to the pull tab 158 to detach the follow plate 154 from the lid 134 when it is desired to load the barrel 115 of the bulk dispensing device with viscous material 118 provided in bulk within the drum 114.

The follow plate 154 of this embodiment 100 includes a disk member 156 which is generally circular and includes a centrally-located hub 160, which is generally cylindrical in shape. As in the first embodiment, the follow plate 154 may include a plurality of ribs 164 extending radially from the hub 160 to outer periphery 156 a of the disk member 156 to provide added stiffness to the disk member 156. The disc member 156 may be formed of any suitable rigid plastic material such polypropylene. Attached to and extending radially from the outer periphery 156 a of the disk member 156 is a relatively soft and flexible overmold 168, which extends to the inside wall of the drum 114.

The overmold 168 may be formed of any suitable material, such as PVC or TPE (thermoplastic elastomer), and as demonstrated in FIGS. 9-11, actually reduces in thickness as it extends radially and approaches the inside wall of the drum 114. As is often the case, the rigid plastic drum 114 may reduce slightly in circumference as it extends from its upper edge 130 downwardly to the bottom surface of the drum 114. As best shown by comparing FIGS. 10 and 11, during use, once detached from the lid 134, the follow plate 154 incrementally advances downwardly towards the bottom of the drum 114 to enable repeated loadings of the barrel 115. During this movement, the outer edge 168 a of the overmold 168 actually bends or flexes upwardly against the inside wall of the drum 114 to permit the follow plate 154 to continue its downward advancement into the drum 114 during incremental loadings of viscous material 118 into the barrel 115. In this manner, the substantial majority of viscous material 118 contained within the drum 114 may be withdrawn into the barrel 115 of the dispensing device resulting in only a minimal amount of waste and leakage across the follow plate 154. Due to the stiffness of the disk member 156, during use, the disk member 156 in combination with the overmold 168 serves to prevent adhesive or caulk material within the drum 114 from leaking across the follow plate 154 as the follow plate 154 is pressed down into the drum 114 during loading of the barrel 115.

A gasket 172 is provided to encircle the centrally-located hub 160 of the disk member 156. Like the overmold 168, the gasket 172 may be formed of any suitable material such as PVC or TPE (thermoplastic elastomer) and serves to provide a seal between the barrel 115 and the hub 160. Under this embodiment, the gasket 172 may be sized to fit over the outer diameter of the hub 160 of the follow plate 154 during loading. Prior to loading, a cap 173 (FIGS. 9 and 10) is arranged to be fitted over the gasket 172 surrounding the central hub 160 and may be removed from the gasket 172 by applying a pulling force to a pull tab 175 integral with the cap 173. The pull tab 175 may be similar to a “tamper-evident” ring commonly used on a plastic milk container. In one embodiment, once the cap 173 has been removed from the gasket 172 surrounding the central hub 160, the barrel 115 may be placed within the hub 160 to provide an interference fit between the outer diameter of the barrel 115 and the inner diameter of the hub 160 to create a seal for drawing viscous material 118 into the dispensing device barrel 115. The gasket 172 prevents leakage across the follow plate 154 during loading. Under this embodiment, there are no internal or external threads utilized for securing the barrel 115 to the hub 160, although such a mechanism for attachment is contemplated under this invention.

It is understood that the container assembly including a detachable follow plate and its constituent parts described herein is an exemplary indication of a preferred embodiment of the invention, and is given by way of illustration only. In other words, the concept of the present invention may be readily applied to a variety of preferred embodiments, including those disclosed herein. While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. 

What is claimed is:
 1. A container assembly including a built-in follow plate for loading a viscous fluid into the barrel of a bulk dispensing device, said assembly comprising: a. a drum for holding a viscous fluid therein, said drum including an open top, a central axis, and an inner side wall; b. a lid including a peripheral channel arranged for fitting over said drum open top to effect closure thereof, and an annular skirt extending inwardly from said peripheral channel to define a central opening through which the barrel of a dispensing device may be extended; and, c. a horizontally oriented follow plate detachable from said lid and including an opening arranged for receiving the barrel of a dispensing device, said follow plate being movable by external means along the central axis of the drum in response to a change in the level of viscous fluid in the drum as it is drawn through the opening and into the barrel of the bulk dispensing device, said follow plate including an inner region and an outer peripheral region in sliding engagement with said drum inner side wall.
 2. A container assembly as set forth in claim 1, wherein said annular skirt includes a bottom surface, said assembly additionally comprising a pull tab formed of a sheet material and interposed between said lid assembly and said follow plate, upon which force is applied to detach said follow plate from said lid assembly.
 3. The container assembly as set forth in claim 1, wherein said opening is a central hub.
 4. The container assembly as set forth in claim 1, wherein said inner region includes a predetermined thickness and wherein said outer peripheral region includes a thickness that is less than said predetermined thickness.
 5. The container assembly as set forth in claim 3, wherein said container assembly additionally comprises a cap for covering said central hub.
 6. The container assembly as set forth in claim 5, wherein said cap assembly additionally comprises a pull tab for removing said cap from said central hub.
 7. The container assembly as set forth in claim 1, wherein said viscous material is a caulking material.
 8. The container assembly as set forth in claim 1, wherein said viscous material is an epoxy material.
 9. A container assembly including a built-in follow plate for loading a viscous fluid into the barrel of a bulk dispensing device, said assembly comprising: a. a drum for holding a viscous fluid therein, said drum including an open top, a central axis, and an inner side wall; b. a lid including a peripheral channel arranged for fitting over said drum open top to effect closure thereof, and an annular skirt extending inwardly from said peripheral channel to define a central opening through which the barrel of a dispensing device may be extended; and, c. a horizontally oriented follow plate detachable from said lid and including an opening arranged for receiving a connection, said follow plate being movable by external means along the central axis of the drum in response to a change in the level of viscous fluid in the drum as it is drawn through the opening and into the barrel of the bulk dispensing device, said follow plate including an inner region and an outer peripheral region in sliding engagement with said drum inner side wall.
 10. The container assembly as set forth in claim 1, wherein said connection is a member selected from the group consisting of a hose, a pipe, or a tube.
 11. The container assembly as set forth in claim 4, wherein said inner region and said outer region have equal predetermined thicknesses.
 12. The container assembly as set forth in claim 4, wherein said inner is comprised of a material that is different from said outer region.
 13. The container assembly as set forth in claim 1, wherein said viscous material is an edible food.
 14. A follow plate for loading viscous fluid into the barrel of a bulk dispensing device, the follow plate being arranged for use in combination with a container assembly arranged for containing a viscous fluid therein, the container assembly having a drum including an inner side wall, an open top, and a lid arranged for fitting over the open top of the drum to effect closure thereof, said follow plate comprising: a. a disk member detachably connected to the lid of the container assembly, said disk member including a centrally located hub that is open at both ends, cylindrical in shape, and arranged for attachment to the barrel of a bulk dispensing device, said disk member further including an outer periphery of generally circular shape; b. a overmold member being generally circular in shape and including a central opening in which said disk member is disposed, said overmold member extending radially from the outer periphery of said disk member to contact the inner side wall of the drum; and, c. said follow plate being movable by external means along the central axis of the drum in response to a change in the level of viscous fluid in the drum as said viscous material is drawn through said hub and into the barrel of the bulk dispensing device.
 15. The follow plate of claim 14, wherein said disk member is formed of a rigid plastic material.
 16. The follow plate of claim 14, wherein said disk member additionally comprises at least one rib extending radially from said hub to said outer periphery.
 17. The follow plate of claim 14, wherein said disk member is formed of polypropylene.
 18. The follow plate of claim 14, wherein said overmold member is reduced in thickness as it extends radially from the outer periphery of said disk member to the inner side wall of the drum.
 19. The follow plate of claim 18, wherein said overmold bends against the inner side wall of the drum during downward advancement of the follow plate during loading of viscous fluid into the barrel of the bulk dispensing device. 